2. Install the slave unit onto the studs in the transmission shift bar cover, making sure that the shift finger engages properly with the shift bars inside the transmission.
3. Position the gearshift lever in neutral (perpendicular) position and install the shift control shaft being careful to maintain the exact position of the slave unit input shaft and the gearshift lever.
4. After installing the shift control shaft and making sure that master and slave unit are synchronized in exact neutral position, tighten the set screws on the shift control shaft universal joint yokes. There are two set screws
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1. Level Ball I. Universal Joint 34. Boot
3. Lever Boot 19. Shift Control Shaft 35. Boot Clamp
4. Shill Control Tower 20. Universal Joint 36. Shaft and Lever
5. Capscrew 21. Lockscrew 37. Outer Shift Shaft
6. Lever Seat 22. Expansion Plug 38. Inner Shift Finger
7. Seat Washer 23. Scraper 39. Finger Capscrew
8. Tower Gasket 24. Housing 40. Housing Assembly
9. Pivot Pin 25. Hex Nut 41. Bushing
10. Hex Nut 26. Hex Nut 42. Scraper
I1. Lockwasher 27. Stud 43. Cap
12. Gasket 28. Breather 44. Lubrication
13. Lockwasher 29. Cover Fitting
14. Gasket 30. Capscrew 45. Bushing
15. Yoke 31. Gasket 46. Scraper
16. Capscrew 32. Finger
Illustration 4-29. Gear Shift Linkage 4-96
TM 5-3810-300-24 & P2
on each yoke mounted at 90 degrees to each other. Lockwire these set screws after tightening.
5. Lubricate the master control unit with chassis lube after installation. The lube fitting is located in the cap just under the shift control shaft.
Range Control Valve.
DISASSEMBLY (Illus. 4-30).
The range control valve is disassembled by removing the top plate screw.
REASSEMBLY.
Reassembly is the reverse of disassembly. Critical assembly factors are:
1. Make sure that the jam nut locking the control valve to the shifting lever is secure.
2. Make sure that, when reassembled, the top plate screw is torqued with 90 to 120 inch-pounds. A loose top plate screw can affect valve operation.
3. When reassembling, lubricate the O-ring and O-ring carrier with a barium base grease.
TROUBLESHOOTING.
Troubleshoot the valve by checking air flow from the ports listed below.
1. Porting There are four ports in the bottom of the control:
a. The port stamped "S" is the supply port and is the constant air line from the air valve.
b. The port stamped "E" is the exhaust port and is left open.
c. The port stamped "R" is the signal line to the slave air valve.
d. The port stamped "F" is the signal line to the intermediate shift cylinder.
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Illustration 4-30. Range Control Valve Disassembly.
1. With the range control in "LOW" position, disconnect the two lines connected to port "R" and "F". There should be no air coming out of these ports.
2. Move the range control to "INTER". There should now be a steady flow of air coming from the "F" port, but still no air coming from the "R" port.
3. Move the range control valve to the "DIR", position. There should now be a steady flow of air coming from both the
"F" and "R" ports.
4. If the above results are not obtained, disconnect the supply air line at the "S" port and make sure that a steady flow of air is coming through the line. If air is present, this would indicate a faulty control valve. Cause can be defective parts, damaged O-ring of loose top plate screw.
5. Any steady flow of air from the range control valve exhaust port indicates a faulty range control valve or incorrect hook-up. Cause can be damaged O-ring, defective parts, loose top plate screw or reversed air lines on the control.
Air Valve and Filter Assembly.
MAINTENANCE (Illus. 4-31).
The air regulator is not serviceable. If defective replace. Reading at output of air regulator should be 57 to 62 psi.
Disassemble air filter in accordance with index numbers (B). Reassembly is the reverse if disassembly.
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TM 5-3810-300-24 & P2
A. Air Valve B. Air Filter
2. End Cap 8. Side Cap 13. Spring
3. O-Ring 9. Valve Insert 14. Gasket
4. Housing 10. O-Ring 15. Plug
5. Piston 11. Insert Spring 16. End Cap
6. O-Ring 17. Plate
Illustration 4-31. Air Valve and Air Filter Assembly.
4-99
REMOVAL.(Illus. 4-8 ).
Refer to Transmission Disassembly for Slave Air Valve Removal.
DISASSEMBLY. (Illus. 4-31).
1. Turn out the two capscrews and remove the side cap from valve body.
2. Remove the valve insert from piston and remove O-ring from the valve inlet.
3. Remove the spring from piston.
4. Turn end cap from valve body, and withdraw piston from bore.
5. Remove the two-rings from piston.
6. Remove the nylon plug from piston, and remove O-ring from plug.
REASSEMBLY.
Reassembly is the reverse of disassembly. Therefore no procedures are given.
Replace all O-ring seals.
INSTALLATION.
Installation is the reverse of removal. Therefore no installation procedures are given.
TRANSMISSION TROUBLESHOOTING.
Listed below are troubles that may occur.
TRANSMISSION TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
Excessive lever travel Set screws loose in control Tighten or replace or sloppy feel when shaft universal joints or set screws.
shifting shift fingers.
Hard shifting Bent shift bar in transmission Disassemble and repair as necessary.
Damaged cross shaft or bushings in master or slave unit.
Transmission locked Shift control shaft broken. U- Disassemble and repair in gear or in neutral; joints loose or disconnected, as required.
gearshift lever moves cross shaft in slave unit bro-freely; no detent ken or shift fingers loose.
feel.
Gearshift lever po Lever in master unit and cross Shift transmission to sitions do not corres- shaft in slave unit out of phase. neutral. Disconnect U
pond to transmission joints at shift control
gear ranges slave unit; place
gear-shift lever in neutral 4-100
TM 5-3810-300-24 & P2
Noise (from other Fan bent or out of balance Replace fan.
sources) Damaged vibration damper Replace damper.
Crankshaft out of balance Check balance. Replace crankshaft if neces-sary.
Flywheel out of balance Check balance. Re-place flywheel if nec-essary.
Unbalanced clutch assembly Check clutch and clutch housing for proper alignment.
Loose engine mountings Tighten mountings.
Worn universal joints Replace universal joints.
Sprung driveshaft Replace driveshaft.
Noisy transmission Transmission misaligned Align engine and
trans-(in neutral) mission (assembled)
with rear axle so as to correct angles of universal joints.
Worn transmission pinion Replace bearing.
bearing.
Worn or scored countershaft Replace bearings.
bearings.
Damaged second speed mainshaft Replace bushing.
gear bushing.
Unmatched gears. Replace unmatched
gears.
Worn or rough reverse-idler Replace gear.
gear.
Eccentric countershaft gear Replace gear.
assembly.
Sprung or worn countershaft. Replace countershaft.
Excessive backlash in gears. Replace worn gears.
Excessive end play in counter- Adjust to reduce end play.
shaft, reverse-idler pinion.
Worn mainshaft pilot bearing. Replace pilot bearing.
Scuffed gear tooth contact sur- Replace gear.
face.
Insufficient lubrication. Check for leaks; fill to proper level.
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